Saw assembly with pivot hinge dust port

ABSTRACT

A saw assembly includes a drive member, a motor, a housing, and a foot. The drive member is configured to be moved in a repeating pattern. The motor is configured to move the drive member in the repeating pattern. The housing defines an interior space in which the motor is positioned. The foot includes (i) a base having an upper surface and a lower work piece contact surface, and (ii) a conduit structure secured to the upper surface of the base. The housing is pivotably mounted to the conduit structure.

FIELD

This patent relates generally to power tools and particularly to powertools having a dust port for use with a dust collection system.

BACKGROUND

Circular saws are a type of power tool used for cutting and shapingworkpieces, such as, hardwood, manufactured wood products, constructionlumber, and other materials. The typical circular saw includes acircular blade, which generates dust and debris as the rotating blade ismoved through the workpiece during a cut. Generally, the dust and debrisinterferes with the cutting task by obstructing the user's view of theworkpiece and diffusing into the surrounding air space. Accordingly, itis desirable to collect the dust generated by the circular saw with adust collection system.

Dust collection systems for use with a circular saw include a source ofvacuum that is fluidly connected to the circular saw with a vacuum line.In particular, known circular saws include a dust channel having aninput port and an output port. The input port is positioned to receivethe dust and debris as it is generated by the saw blade. The output portis fluidly connected to the vacuum line. When the source of vacuum isactivated, the dust and debris generated by the circular saw blade isdrawn into the input port, through the dust channel, out the outputport, and through the vacuum line where it is collected in a bin fordisposal or repurposing.

Most users desire a circular saw, which has a housing that is robust andcompact. Some known dust channels, however, increase the size of thehousing, thereby making the circular saw cumbersome to store andtransport. Therefore, it is desirable to provide a circular saw having arobust and compact housing, which incorporates a dust channel that ispositioned to effectively collect the dust and debris generated by thecircular saw blade.

SUMMARY

According to one embodiment of the disclosure a saw assembly includes adrive member, a motor, a housing, and a foot. The drive member isconfigured to be moved in a repeating pattern. The motor is configuredto move the drive member in the repeating pattern. The housing definesan interior space in which the motor is positioned. The foot includes(i) a base having an upper surface and a lower work piece contactsurface, and (ii) a conduit structure secured to the upper surface ofthe base. The housing is pivotably mounted to the conduit structure.

BRIEF DESCRIPTION OF THE FIGURES

The above-described features and advantages, as well as others, shouldbecome more readily apparent to those of ordinary skill in the art byreference to the following detailed description and the accompanyingfigures in which:

FIG. 1 shows a perspective view of a first side of a saw assembly asdescribed herein;

FIG. 2 shows a perspective view of an opposite side of the saw assemblyof FIG. 1;

FIG. 3 shows a cross sectional view taken along the line III-III of FIG.1;

FIG. 4 shows a portion of the cross sectional view of FIG. 3;

FIG. 5 is a front perspective view of a portion of the saw assembly ofFIG. 1, showing a guard structure and a flat cutting wheel;

FIG. 6 is a front perspective view of a portion of the saw assembly ofFIG. 1, showing the guard structure and a flush cutting wheel;

FIG. 7 shows a front elevational view of the flat cutting wheel for usewith the saw assembly of FIG. 1;

FIG. 8 shows a side elevational view of the flat cutting wheel of FIG.7;

FIG. 9 shows a front perspective view of the flush cutting wheel for usewith the saw assembly of FIG. 1;

FIG. 10 shows a side elevational view of the flush cutting wheel of FIG.9;

FIG. 11 is a side elevational view of the saw assembly of FIG. 1 showinga lockout power switch;

FIG. 12 is a perspective view of a portion of the lockout power switchof FIG. 11;

FIG. 13 is an exploded perspective view of a portion of the lockoutpower switch of FIG. 11;

FIG. 14 is a cross sectional view of a portion of the saw assembly ofFIG. 1, showing the lockout power switch in a denergized position;

FIG. 15 is a cross sectional view of a portion of the saw assembly ofFIG. 1, showing the lockout power switch in an energized position;

FIG. 16 is a cross sectional view of a portion of the saw assembly ofFIG. 1, showing a lock on structure for maintaining the lockout powerswitch in the energized position, the lock on structure is shown in adisengaged position;

FIG. 17 is a cross sectional view of a portion of the saw assembly ofFIG. 1, showing the lock on structure in an engaged position;

FIG. 18 is a side elevational view of a portion of the saw assembly ofFIG. 1 showing the guard structure of the saw assembly and the flatcutting wheel;

FIG. 19 is a bottom plan view of the saw assembly of FIG. 1 showing theflush cutting wheel positioned in a protective pocket of the guardstructure;

FIG. 20 is a side perspective view of the saw assembly of FIG. 1 showingthe saw assembly part way through a workpiece cutting operation;

FIG. 21 is a side perspective view of a portion of the saw assembly ofFIG. 1 showing a foot of the saw assembly in a position of maximumcutting depth and also showing a spring for biasing the foot;

FIG. 22 is a side perspective view of a portion of the saw assembly ofFIG. 1 showing the foot of the saw assembly in the position of maximumcutting depth and also showing the spring for biasing the foot;

FIG. 23 is a side perspective view of a portion of the saw assembly ofFIG. 1 showing the foot of the saw assembly in a position of minimumcutting depth and also showing the spring for biasing the foot;

FIG. 24 is a top perspective view of a portion of the saw assembly ofFIG. 1 showing the spring of FIG. 21 as it is received by the foot;

FIG. 25 is a perspective view of a portion of the saw assembly showingan inlet dust port and an adapter;

FIG. 26 is a perspective view of a portion of the saw assembly of FIG.1, the adapter, and a vacuum hose, additionally a schematic view of avacuum source and a bin is also shown;

FIG. 27 is a perspective view of a portion of the saw assembly of FIG. 1showing an inside surface of the dust port;

FIG. 28 is a perspective view of the adapter of FIG. 25;

FIG. 29 is a perspective view of a portion of saw assembly of FIG. 1,showing a portion of a base lock assembly;

FIG. 30 is a perspective view of a clamp component of the base lockassembly of FIG. 29;

FIG. 31 is a perspective view of a knob of the base lock assembly ofFIG. 29;

FIG. 32 is a perspective view of a portion of the saw assembly of FIG. 1showing another portion of the base lock assembly of FIG. 29;

FIG. 33 is a side elevational view of a portion of the saw assembly ofFIG. 1 showing a depth gauge and also showing the foot in the positionminimum cutting depth;

FIG. 34 is a top elevational view of a portion of the saw assembly ofFIG. 1 having a T-square assembly attached thereto;

FIG. 35 is a bottom perspective view of a portion of the saw assembly ofFIG. 1 and the T-square assembly of FIG. 34;

FIG. 36 is a top perspective view of the saw assembly of FIG. 1 and theT-square assembly of FIG. 34 part way though a workpiece cuttingoperation;

FIG. 37 shows a bottom perspective view of the saw assembly of FIG. 1with a portion of a housing of the saw assembly removed to show a gearhousing of the saw assembly;

FIG. 38 is a side elevational view showing the saw assembly of FIG. 1connected to a table saw assembly;

FIG. 39 shows a top perspective view of a cutting guide for use with thesaw assembly of FIG. 1;

FIG. 40 shows a top plan view of the cutting guide of FIG. 39;

FIG. 41 shows a bottom perspective view of the cutting guide of FIG. 39;

FIG. 42 shows a top perceptive view of the saw assembly of FIG. 1 andthe cutting guide of FIG. 39, the saw assembly positioned to make abevel cut through a workpiece;

FIG. 43 shows a bottom perspective view of the saw assembly of FIG. 1and the cutting guide of FIG. 39, with the cutting wheel of the sawassembly extending through a cutting slot of the cutting guide;

FIG. 44 shows a top perspective view of a cutting guide for use with thesaw assembly of FIG. 1;

FIG. 45 shows a top plan view of the cutting guide of FIG. 44;

FIG. 46 shows a bottom perspective view of the cutting guide of FIG. 44;

FIG. 47 shows a bottom plan view of the cutting guide of FIG. 44;

FIG. 48 shows a bottom perspective view of the foot of the saw assemblyof FIG. 1 in isolation;

FIG. 49 shows a rear perspective view of the foot of the saw assembly ofFIG. 1 in isolation;

FIG. 50 is a bottom perspective view of the saw assembly of FIG. 1 andthe cutting guide of FIG. 39;

FIG. 51 is a perspective view of a deburring accessory for use with thesaw assembly of FIG. 1;

FIG. 52 is a perspective view of the deburring accessory of FIG. 51connected to the power saw of FIG. 1;

FIG. 53 is a top plan view of the deburring accessory of FIG. 51; and

FIG. 54 is a cross sectional view taken along the line III-III of FIG.53 showing the deburring accessory positioned to deburr a first pipe anda second pipe;

DETAILED DESCRIPTION

For the purpose of promoting an understanding of the principles of thedisclosure, reference will now be made to the embodiments illustrated inthe drawings and described in the following written specification. It isunderstood that no limitation to the scope of the disclosure is therebyintended. It is further understood that the disclosure includes anyalterations and modifications to the illustrated embodiments andincludes further applications of the principles of the disclosure aswould normally occur to one skilled in the art to which this disclosurepertains.

As shown in FIGS. 1 and 2, a saw assembly 100 includes a housing 104.The housing 104 includes a sleeve 108, a rearward housing portion 110having an upper left shell 112 and an upper right shell 116, and aforward housing portion 118 having a lower left shell 120 and a lowerright shell 124. The upper left shell 112 and the upper right shell 116are connected to a rearward side of the sleeve 108, and the lower leftshell 120 and the lower right shell 124 are connected to a forward sideof the sleeve. Movement from the rearward housing portion 110 to theforward housing portion 118 is defined herein to be in the forwarddirection 126. While movement from the forward housing portion 118 tothe rearward housing portion 110 is defined herein to be in the rearwarddirection 130. The housing 104 is formed from injection moldedthermoplastic and defines an interior space 128 (FIG. 3) within thehousing.

Drivetrain

As shown in FIG. 3, a drivetrain 132 is at least partially positionedwithin the interior space 128 defined by the housing 104. The drivetrain132 includes an electric motor 136, a worm gear 140, a drive member 144,and an arbor assembly 148 (FIG. 1). The electric motor 136 is at leastpartially positioned within the interior space 128 and includes a stator152 and a rotor 156. The stator 152 is fixedly connected to the sleeve108 of the housing 104 within the internal space 128. The stator 152generates a magnetic field within a rotor space 164.

The rotor 156 includes a winding portion 168 and a motor shaft 172. Thewinding portion 168 is fixedly connected to the motor shaft 172 and ispositioned at least partially within the rotor space 164. The motorshaft 172 is a generally cylindrical metal shaft, which extends from therotor space 164 and is supported for rotation relative to the stator 152and the housing 104 about a motor axis 176. The rotor 156 and the motorshaft 172 rotate relative to the stator 152 and the housing 104 when theelectric motor 136 is supplied with electrical energy.

With reference to FIG. 3, the motor 136 is supplied with electricalenergy through an electrical cord 178 extending through a rear housingopening 182. It is noted that the forward direction 126 may also bedefined herein as the path of movement from the electrical cord 178toward the drive member 144

As shown in FIG. 4, the motor shaft 172 includes a set of externalthreads 180 and a smooth shaft portion 184 and defines a shoulder 188.The external threads 180 are located on an end portion 192 of the motorshaft 172. The smooth shaft portion 184 is located between the externalthreads 180 and the shoulder 188. The smooth shaft portion 184 is acylindrical portion of the motor shaft 172.

The worm gear 140 is positioned in the internal space 128 of the housing104 and, in particular, is positioned within a metal gear housing 196(FIG. 3). The worm gear 140 includes a set of worm gear teeth 200, abore structure 204, and a worm gear shaft 208. The bore structure 204defines a blind bore 212 and an opening 216, which leads to the blindbore. The bore structure 204 includes a set of internal threads 220 anda smooth bore portion 224. The internal threads 220 are positionedwithin the blind bore 212 at a position that is spaced apart from theopening 216. The internal threads 220 are configured to meshingly engagewith the external threads 180 of the motor shaft 172 to connect the wormgear 140 to the motor shaft 172. The smooth bore portion 224 ispositioned within the blind bore 212 between the internal threads 220and the opening 216.

With reference to FIG. 4, the worm gear shaft 208 is coupled to themotor shaft 172, such that rotation of the motor shaft causes rotationof the worm gear 140 about the motor axis 176. In particular, theexternal threads 180 are located within the blind bore 212, such thatthe external threads are meshingly engaged with the internal threads 220to connect the worm gear 140 to the motor shaft 172. As the externalthreads 180 are meshingly engaged with the internal threads 220, theopening 216 is moved closer to the shoulder 188. When the worm gearshaft 208 is coupled to the motor shaft 172, the opening 216 ispositioned adjacent to the shoulder 188.

The smooth bore portion 224 of the bore structure 204 interacts with thesmooth shaft portion 184 of the motor shaft 172 to accurately align theworm gear 140 with the motor shaft 172. To this end, the smooth shaftportion 184 defines an outside diameter 222 and the smooth bore portiondefines an inside diameter 226. The outside diameter 222 and the insidediameter 226 are substantially equal (the outside diameter is slightlysmaller than the inside diameter to allow entry of the motor shaft 172into the bore 224), such that the smooth shaft portion 184 fills thesmooth bore portion 224 causing the worm gear 140 to become aligned withthe motor shaft 172.

As shown in FIG. 3, the motor shaft 172 and the worm gear 140 aresupported by a floating bearing 228, a floating bearing 232, and afloating bearing 236. The floating bearing 236 supports a right endportion of the motor shaft 172, the floating bearing 232 supports a leftend portion of the motor shaft, and the floating bearing 228 supports aleft end portion of the worm gear 140.

As shown in FIG. 4, the floating bearing 228 includes an inner race 240,an outer race 244, numerous ball bearings 248, and an elastomericsupport member 252. The inner race 240 is fixedly connected to the wormgear 140 for rotation with the worm gear. The ball bearings 248 arepositioned between the inner race 240 and the outer race 244. The outerrace 244 is received by the elastomeric support member 252. Theelastomeric support member 252 is received by the gear housing 196. Theinner race 240 is configured to rotate relative to the outer race 244and the elastomeric support member 252 in response to rotation of theworm gear 140. The floating bearing 232 and the floating bearing 236 aresubstantially identical, except that the inner races of the floatingbearings 232, 236 are fixedly connected to the motor shaft 172 and theelastomeric support of the floating bearing 236 is received by thehousing 104.

The floating bearing 228 is referred to as “floating” since theelastomeric support member 252 enables movement of the inner race 240and the outer race 244 relative to the gear housing 196 and the housing104. Accordingly, the floating bearings 228, 232, 236 are suited todampen vibrations of the motor shaft 172 and the worm gear 140, whichoccur due to machine tolerances and other factors, which cause the motorshaft and the worm gear to be slightly unbalanced. The floating bearings228, 232, 236 dampen these vibrations so that the saw assembly 100 iscomfortable to hold during cutting operations.

With reference to FIG. 4, the drive member 144 of the drivetrain 132 isoperably coupled to the worm gear 140 and includes a pinion gear 256 anda driveshaft 260 both of which are at least partially positioned withinthe gear housing 196. The pinion gear 256 includes a set of gear teeth264 positioned to meshingly engage the worm gear teeth 200. Thedriveshaft 260 is fixedly connected to the pinion gear 256, such thatrotation of the worm gear 140 results in movement of the driveshaft in arepeating pattern. Specifically, when the electric motor 136 isenergized, rotation of the motor shaft 172 and the worm gear 140 resultsin rotation of the driveshaft 260 about an axis of rotation 268 (seeFIG. 1, extends into and out of the page in FIG. 4), which isperpendicular to the motor axis 176 of the motor shaft 172. The axis ofrotation 268 and the motor axis 176 are not coincident. The motor axis176 is perpendicular to a motor axis plane 272 and the axis of rotation268 of the driveshaft 260 and the pinion gear 256 is perpendicular to adriveshaft plane 278 (not shown, parallel to a face 280 of the piniongear 256). The motor axis plane 272 is perpendicular to the driveshaftplane 278. A portion of the driveshaft 260 extends through an opening282 (FIG. 1) in the lower right shell 124 of the forward housing portion118.

As shown in FIG. 5, the arbor assembly 148 includes an arbor bolt 284, aspacer 288 (also shown in FIG. 19), and a washer 292. The arbor bolt 284extends through an opening (not shown) of the spacer 288, an opening(not shown) of the washer 292, and is threadingly received by a threadedopening (not shown) of the driveshaft 260. The arbor assembly 148connects a flat cutting wheel 296 to the saw assembly 100 for rotationwith the driveshaft 260. As shown in FIG. 6, the arbor assembly 148connects a flush cutting wheel 300 to the saw assembly 100 for rotationwith the driveshaft 260.

As shown in FIGS. 7 and 8, the flat cutting wheel 296, which is alsoreferred to herein as a flat cutoff wheel or a flat saw member, isgenerally circular and includes a flat hub portion 304 and a cuttingstructure 308. The hub portion 304 defines an opening 312 in the centerof the cutting wheel 296 through which the arbor bolt 284 extends whenthe cutting wheel is mounted to the driveshaft 260. The cuttingstructure 308 is positioned on the periphery of the cutting wheel 296.As shown in FIG. 8, a plane 316 extends through the hub portion 304 andthe cutting structure 308. The cutting structure 308 is abrasive and isat least partially formed form carbide.

As shown in FIGS. 9 and 10, the flush cutting wheel 300 is generallycircular and includes a domed hub portion 320 and a cutting structure324. The domed hub portion 320 defines an opening 328 in the center ofthe cutting wheel 300 through which the arbor bolt 284 extends when thecutting wheel is mounted to the driveshaft 260. The cutting structure324 is positioned on the periphery of the cutting wheel 300. A hub plane332 extends through the hub portion 320, and a cutting plane 336 extendsthrough the cutting structure 324. The hub plane 332 is parallel to thecutting plane 336 and is offset from the cutting plane, such that thecutting plane extends further from the arbor assembly 148 than does theplane 316 of the flat cutting wheel 296 when the cutting wheel 300 ismounted on the driveshaft 260.

The cutting structure 308 of the cutting wheel 296 and the cuttingstructure 324 of the cutting wheel 300 each include numerous scallops340. The scallops 340 assist in removing debris from a kerf formed in aworkpiece during cutting operations.

The cutting structure 308 and the cutting structure 324 differentiatethe cutting wheel 296 and the cutting wheel 300 from traditional sawblades (not shown) that include cutting teeth. Accordingly, when one ofthe cutting wheels 296, 300 is connected to the saw assembly 100, thesaw assembly may be referred to as a grinder or a circular saw. When atraditional saw blade is connected to the saw assembly 100, the sawassembly may be referred to as a circular saw.

Lockout Power Switch

As in FIGS. 11, 12, and 13, the saw assembly 100 includes a power lever342 for operating a switch unit 394 (FIG. 14) that couples electricalenergy to the electric motor 136. The power lever 342 includes a triggerreferred to herein as a paddle 344, a lockout lever 346, and a spring348 (FIGS. 12 and 13).

The paddle 344 includes a pivot structure 350 and an abutment structure352 and defines a paddle cavity 354 and a contact surface 356. The pivotstructure 350 is positioned on an end portion of the paddle 344 andincludes a barb 360. The barb 360 of the pivot structure 350 ispositioned within the interior space 128 defined by the housing 104.Specifically, when the barb 360 is inserted into the housing 104 itinterlocks with the housing to prevent the paddle 344 from being removedfrom the housing.

The paddle 344 pivots about the pivot structure 350 between an offposition (also referred to herein as the de-energized position) (FIG.14) and an on position (also referred to herein as the energizedposition) (FIG. 15) about a path of movement 362. As shown in FIG. 11,the paddle 344 at least partially extends through a housing opening 358formed in both the sleeve 108 and the rearward housing portion 110.

As shown in FIG. 14, the abutment structure 352 is positioned on anopposite end portion of the paddle 344 and is at least partiallypositioned within the interior space 128 of the housing 104. Theabutment structure 352 includes a switch surface 364 located on a topside of the abutment structure and a catch feature or lock-on notch 366located on a bottom/opposite side of the abutment structure. The switchsurface 364 is positioned to engage an actuator 398 of a switch unit 394of the saw assembly 100. The lock-on notch 366 cooperates with a lock-onstructure 402 of the saw assembly 100, as described below.

With reference to FIG. 13, the paddle cavity 354 is formed in the paddle344 between the pivot structure 350 and the abutment structure 352 on anouter side of the paddle, which faces away from the electric motor 136.The paddle cavity 354 defines a generally concave paddle cavity surface372 (FIG. 15). The paddle cavity 354 receives at least a portion of thelockout lever 346 and at least a portion of the spring 348. The paddlecavity 354 has a length of approximately 2.5 centimeters (2.5 cm) and awidth of approximately 2.0 centimeters (2.0 cm).

The paddle 344 includes an opening 368, an opening 370, and a leveropening 374 (FIGS. 14 and 15). The opening 368 and the opening 370 arein fluid communication with the paddle cavity 354 and are used topivotally connect the lockout lever 346 to the paddle, as describedbelow. The lever opening 374 is formed in the cavity surface 372 andfluidly couples the interior space 128 to the paddle cavity 354.

The contact surface 356 is at least a portion of the outer side of thepaddle 344. The contact surface 356 is a portion of the power lever 342that a user contacts to use the power lever. The contact surface 356 isa convex surface such that fits comfortably in the hand of the user. Thecontact surface 356 has a width of approximately 2.3 centimeters (2.3cm) and a length of approximately 6.0 centimeters (6.0 cm).

The lockout lever 346 includes a finger contact portion provided as anactuator portion 376, a connection structure 378, and a blocking memberprovided as a lockout tab 380. The actuator portion 376 extends from theconnection structure 378 and is generally semicircular in shape.

The connection structure 378 defines a pivot opening 382 for receiving apivot shaft 384. In particular, the pivot shaft 384 extends through theopening 368, the pivot opening 382, and the opening 370 to pivotallyconnect the lockout lever 346 to the paddle 344. The lockout lever 346extends through the lever opening 374 formed in the paddle 344 and intothe interior space 128. The lockout lever 346 pivots about the pivotshaft 384 between a lockout or locked position (FIG. 14) and anon-lockout or an unlocked position (FIG. 15).

The lockout tab 380 extends from the connection structure 378 and is atleast partially positioned in the interior space 128. The lockout tab380 is positioned on a generally opposite side of the connectionstructure 378 from the actuator portion 376. As shown in FIG. 14, whenthe lockout lever 346 is in the locked position, the lockout tab 380 ispositioned in a first location relative to the paddle 344 against a stopstructure 386 of the housing 104. As shown in FIG. 15, however, when thelockout tab 380 is in the unlocked position, the lockout tab is moved toa second position relative to the paddle 344 away from the stopstructure 386.

With reference again to FIG. 13, the spring 348 is a torsion spring,which includes a coil 388, an arm 390, and an arm 392. The pivot shaft384 extends through the coil 388 to position the arm 392 against thecavity surface 372 and the arm 390 against the actuator portion. 376.The spring 348 biases the lockout lever 346 toward the locked position,as shown in FIG. 14. In particular, the spring 348 biases the actuatorportion 376 in the rearward direction 130 (FIG. 14) and biases thelockout tab 380 in the forward direction 126 (FIG. 14).

As shown in FIG. 14, the switch unit 394 that is operated by the powerlever 342 includes a switching element 396 and an actuator 398positioned in the interior space 128 of the housing 104. The actuator398 is movable between an actuated position (FIG. 15) and a deactuatedposition (FIG. 14). When the actuator 398 is in the actuated positionthe switching element 396 couples electrical energy to the electricmotor 136 and the electric motor operates to move the driveshaft 260 inthe repeating pattern. When the actuator 398 is in the deactuatedposition the switching element 396 decouples electrical energy from theelectric motor 136 and the motor does not operate to move the driveshaft260 in the repeating pattern. The actuator 398 is spring biased in thedeactuated position. The actuator 398 contacts the switch surface 364 ofthe paddle 344 to bias the paddle toward the de-energized position.

The power lever 342 prevents users from inadvertently energizing theelectric motor 136. As shown in FIG. 14, the paddle 344 is in thede-energized position and the lockout lever 346 is in the lockedposition. When the lockout lever 346 is in the locked position, thelockout lever prevents the paddle 344 from being moved to the energizedposition due to physical interaction of the lockout tab 380 and the stopstructure 386. In particular, as shown in FIG. 14, the lockout tab 380is positioned against the stop structure 386 to prevent movement of thepaddle 344. Pivotal forces imparted on the paddle 344 which tend to movethe abutment structure 352 toward the electric motor 136 about the pathof movement 362, wedge the lockout tab 380 against the stop structure386 and the portion 400 of the paddle, such that no pivotal movement ofthe paddle occurs.

With reference to FIGS. 14 and 15, when the lockout lever 346 is in theunlocked position movement of the paddle 344 to the energized positionis enabled due to the lockout tab 380 being moved away from the stopstructure 386. Accordingly, to energize the electric motor 136, firstthe lockout lever 346 is moved to the unlocked position and then thepaddle 344 is pivoted to the energized position. The lockout lever 346is pivoted to the unlocked position by moving the actuator portion 376in the forward direction 126. Pivoting of the lockout lever 346 istypically done by pressing the tip of the little finger against theactuator portion 376 and then squeezing the actuator portion against thecavity surface 372. The forward direction 126 movement of the actuatorportion 376 causes the lockout tab 380 to move in the rearward direction130.

The actuator 398 is moved to the energized position and the switch 394energizes the electric motor 136 in response to the paddle 344 moving tothe energized position. As shown in FIG. 15, when the lockout lever 346is in the unlocked position the lockout tab 380 is positioned behind thestop structure 386, such that the lockout tab is misaligned with thestop structure and does not interfere with pivoting of the paddle 344.The paddle 344 is moved to the energized position by squeezing thepaddle. Typically, when moving the paddle 344 to the energized position,the fingers contact the contact surface 356 and the palm contacts anupper side of the sleeve 108. The user moves the paddle 344 to energizedposition by initiating a squeezing movement of the hand, which causesthe paddle to pivot about the pivot structure 350 and also causes theswitch surface 364 to abut the actuator 398 and to move the actuator tothe energized position. It is noted that the saw assembly 100 isconfigured for one hand operation; therefore, the same hand that movesthe lockout lever 346 to the unlocked position is used to move thepaddle to the energized position. The same hand is also used to guidethe saw assembly 100 through the workpiece.

To return the paddle 344 to the de-energized position from the energizedposition the user releases the squeezing force on the paddle 344. Thiscauses the actuator 398 of the switch 394 to pivot the paddle 344 backto the de-energized position. When the paddle 344 is positioned in thede-energized position the actuator 398 is in the deactuated position andthe motor 136 does not operate. Also, when the paddle 344 reaches ornearly reaches the de-actuated position, the torsion spring 348 returnsthe lockout lever 346 to the locked position.

The power lever 342 is positioned on the housing 104 in an ergonomiclocation. The power lever 342 is positioned to be easily contacted bythe user's fingers on an underside of the sleeve 108. Additionally, theforce that the user applies to the saw assembly 100 to move the sawthrough a workpiece assists the user in maintaining the paddle 344 inthe energized position.

As shown in FIGS. 16 and 17, the saw assembly 100 also includes alock-on member or structure 402, which includes a slider 404 and aspring 406. The slider 404 includes a push button portion 408 on a firstend of the slider and a catch feature or a hook member 410 on anopposite second end of the slider. A flange 412 of the slider 404 ispositioned between the push button 408 and the hook member 410.

The slider 404 is at least partially positioned within the internalspace 128. In particular, the slider 404 is positioned in a slidercavity 414. The slider cavity 414 includes a shoulder 416, a shoulder418, and a button opening 420. The slider 404 extends through the buttonopening 420, such that the push button portion 408 is positioned outsideof the internal space 128 and the hook portion 410 is positioned withinthe internal space.

The spring 406 is an extension spring positioned between the flange 412and the shoulder 418. The spring 406 biases the flange 412 against theshoulder 416.

The slider 404 is movable between a non-interference position ordisengaged positioned (FIG. 16) and an interference position or anengaged position (FIG. 17). As shown in FIG. 16, the spring 406 biasesthe slider 404 in the disengaged position. As shown in FIG. 17, theslider 404 is movable to the engaged position by moving the slidertoward the paddle 344 against the biasing force of the spring 406. Whenthe slider 404 is in the engaged position, at least a portion of theslider is in the path of movement 362 of the paddle 344. When the slider404 is in the disengaged position the slider is spaced apart from thepath of movement 362.

The lock on structure 402 maintains the paddle 344 in the energizedposition without user intervention. To lock the paddle 344 in theenergized position, first the paddle is moved to the energized positionalong the path of movement 362. Then, with the paddle 344 in theenergized position, the slider 404 is moved the engaged position.Thereafter, the squeezing force on the paddle 344 is released and theslider 404 maintains the paddle in the energized position. The paddle344 is maintained in the energized position without user-contact of thepower lever 342 or the push button 408.

The hook portion 410 of the slider 404 engages the lock-on notch 366 tomaintain the paddle 344 in the energized position. As shown in FIG. 17,when the paddle 344 is in the energized position and the slider 404 isin the engaged position, the lock-on notch 366 is positioned above thehook portion 410. Accordingly, when the force maintaining the paddle 344in the energized position is released, the lock-on notch 366 becomesseated in the hook portion 410, thereby preventing the paddle fromreturning to the de-energized position. The spring 406 supplies abiasing force that ensures the hook portion 410 and the lock-on notch366 remain engaged without user intervention.

To release the paddle 344 from the lock-on structure, the switch surface364 of the paddle 344 is moved slightly closer to the switching element396 (not shown in FIGS. 16 and 17), which moves the lock-on notch 366away from the hook member 410 and disengages the lock-on notch from thehook member. When lock-on notch 366 and the hook member 410 aredisengaged, the spring 406 returns the slider 404 to the disengagedposition. Thereafter, the force on the paddle 344 may be released toallow the actuator 398 to return the paddle to the disengaged position.

Guard Structure

As shown in FIGS. 5 and 18, the saw assembly 100 includes a guardassembly 422 in which one of flat cutting wheel 296 and the flushcutting wheel 300 are partially positioned. The guard assembly 422 issecured to the housing 104 and includes a concave structure 424, apartition 426, and a flange 428.

The concave structure 424 extends from a wall portion 430 (FIG. 18) ofthe housing 104 and defines a protected space 432 for receiving at leasta portion of one of the cutting wheel 296 and the cutting wheel 300. Thepartition 426 is secured to the concave structure 424 within theprotected space 432. In particular, the partition 426 extends from theconcave structure 424 toward the axis of rotation 268. The flange 428projects from the partition 426 in a direction parallel to the axis ofrotation 268 (FIG. 5). The wall portion 430, the concave structure 424,the partition 426, the flange 428, and the lower right shell 124 areintegrally molded together in a monolithic part formed from injectionmolded thermoplastic.

As shown in FIG. 18, the shape of the partition 426 is defined inrelation to a workpiece contact plane 434 and an arbor plane 436. Theworkpiece contact plane 434 is defined by a workpiece contact surface466 (FIG. 19) of a foot 456 (FIG. 19) of the saw assembly 100. Asdescribed in detail below, the workpiece contact surface 466 ispositioned against and moved across a workpiece during cuttingoperations of the saw assembly 100. The workpiece contact surface 466 isin the workpiece contact plane 434. The axis of rotation 268 is parallelto the workpiece contact plane 434.

The arbor plane 436 is parallel to the workpiece contact plane 434 andintersects the axis of rotation 268. The arbor plane 436 also intersectsa leading portion 438 and a trailing portion 440 of the partition 426.The leading portion 438 is located forward of the axis of rotation 268in relation to the forward direction 126 of movement of the saw assembly100. The arbor plane 436 intersects the leading portion 438 for anamount referred to as the leading intersection distance. The trailingportion 440 of the partition 426 is located behind the axis of rotation268 in relation to the forward direction 126 of movement of the sawassembly 100. The arbor plane 436 intersects the trailing portion 440for an amount referred to as the trailing intersection distance. Theleading intersection distance is less than the trailing intersectiondistance.

As shown in FIG. 19, the partition 426 divides the protected space 432into a cutting wheel space 442 and another cutting wheel space 444. Thecutting wheel space 442 is positioned on a side of the partition 426nearest the wall portion 430, such that the cutting wheel space 442 isinterposed between the wall portion 430 and the partition 426. Thecutting wheel space 444 is positioned an opposite side of the partition426 and is defined by the flange 428.

With reference to FIG. 5, the flange 428, which is also referred toherein as a guard wall, defines a lateral guard wall surface 446 and alower guard wall surface 448. The lateral guard wall surface 446 ispositioned against a workpiece or cutting guide during cuttingoperations that utilize the flush cutting wheel 300. The lateral guardwall surface 446 is angled with respect to the lower guard wall surface448 by approximately ninety degrees (90°). A bevel portion 450 of thelateral guard surface 446/concave structure 424 is beveled with respectto the lower guard wall surface 448.

The guard assembly 422 guards at least two types of cutting wheelsincluding the flat cutting wheel 296 and the flush cutting wheel 300without requiring any user configuration of the guard assembly whenswitching between the cutting wheels. As shown in FIG. 5, the flatcutting wheel 296 is connected to the arbor assembly 148 and is at leastpartially positioned in the cutting wheel space 442 (FIG. 19). When theelectric motor 136 is supplied with electric energy the driveshaft 260rotates the cutting wheel 296 about the axis of rotation 268 so that thecutting structure 308 is advanced through the cutting wheel space 442.

As shown in FIG. 20, the shape of the partition 426 enables a user ofthe saw assembly 100 to view a leading edge 452 of the cutting wheel 296positioned in the cutting wheel space 442 as it moves through aworkpiece W. For example, a cutting line 454 may be drawn on theworkpiece W, representative of a desired cutting path. The shape of thepartition 426 enables the user to view the point of intersection betweenthe leading edge 452 and the cutting line 454 during the cuttingoperation. This simplifies the task of guiding the saw assembly 100along a desired cutting line 454.

As shown in FIG. 6, the flush cutting wheel 300 is connected to thearbor assembly 148 and is at least partially positioned in the cuttingwheel space 444 (FIG. 18). When the electric motor 136 is supplied withelectric energy the driveshaft 260 rotates the cutting wheel 300 aboutthe axis of rotation 268 so that the cutting structure 324 is advancedthrough the cutting wheel space 444.

Pivotable Foot

As shown in FIGS. 21 and 22, the saw assembly 100 includes a foot 456pivotally connected to the housing 104 and biased by a spring 457. Thefoot 456 includes a base 458, a hinge structure 460, and an extensionstructure 462, which are integrally molded together in a monolithic partformed from injection molded thermoplastic.

As shown in FIG. 21, the base 458 defines an upper surface 464, aworkpiece contact surface 466, and a cutting wheel passage 468. Theworkpiece contact surface 466 is positioned against a workpiece W or aguide 780 (FIG. 39) during cutting operations. The base 458 includesnumerous grooves 470 (FIG. 19) to reduce the surface area of theworkpiece contact surface 466, such that the workpiece contact surfaceslides easily on most workpieces.

As shown in FIG. 23, the cutting wheel passage 468 is formed in the base458 and is defined on three sides by the base. The passage 468 has agenerally rectangular shape. The passage 468 is positioned on the sideof the base 458 near the arbor assembly 148, such that a portion of thecutting wheel 296, 300 extends therethrough. The cutting wheel passage468 may also be referred to herein as a base opening.

The hinge structure 460 includes a riser 472 extending from the base 458and a conduit structure or a generally cylindrical member 474 extendingfrom the riser. The riser 472 extends from the upper surface 464. Thecylindrical member 474 defines a central channel 476 that extendscompletely through the cylindrical member and which is defined by anopening 478 and an opening 480 (FIG. 22). The cylindrical member 474also defines a longitudinal axis 482, which is parallel to the axis ofrotation 268. A left portion 484 (FIG. 22) of the cylindrical member 474is positioned on a left side of the riser 472, and a right portion 486(FIGS. 21 and 23) of the cylindrical member is positioned on a rightside of the riser.

The cylindrical member 474 of the hinge structure 460 is received by thehousing 104 to enable the foot 456 to pivot relative to the housing or,stated differently, to enable the housing to pivot relative to the foot.In particular, as shown in FIG. 21, the lower left shell 120 defines ahinge bore 488 or a hinge receptacle, and as shown in FIG. 22, the lowerright shell 124 defines a hinge bore 490 or a hinge receptacle. Thehinge receptacles 488, 490 have an inside diameter that is approximatelyequal to an outside diameter of the cylindrical member 474 to enable thehinge receptacle 488 to receive the left portion 484 and to enable thehinge receptacle 490 to receive the right portion 486. The foot 456 ispivotable about the hinge structure 460 relative to the housing 104about a pivot axis 492 that is coaxial with the longitudinal axis 482.The foot 456 is shown in FIGS. 21 and 22 pivoted to a position ofmaximum cutting depth (also referred to as the non-rest position) and isshown in FIG. 23 pivoted to a position of minimum cutting depth (alsoreferred to as the rest position).

As shown in FIG. 23, the extension structure 462 includes a lower endportion 494 and an upper end portion 496 and defines an opening 498. Thelower end portion 494 is attached to the upper surface 464. Theextension structure 462 extends from the base 458 along a generallyarcuate path into the interior space 128, such that the upper endportion 496 is positioned in the interior space. The opening 498 is agenerally arcuate opening that extends from near the lower end portion494 to near the upper end portion 496. The opening 498 cooperates with abase lock assembly 576 (FIG. 27) for fixing the position of the foot 456relative to the housing 104.

As shown in FIG. 24, the upper end portion 496 defines a spring armcontact surface 500 for contacting the spring 457 and includes aprotrusion 502 and a protrusion 504. The protrusion 502 extends from theupper end portion 496, such that a portion of the protrusion 502 ispositioned above the spring arm contact surface 500. Similarly, theprotrusion 504 extends for an approximately equal distance from theupper end portion 496, such that a portion of the protrusion 504 ispositioned above the spring arm contact surface 500. The protrusion 502is spaced apart from the protrusion 504 so as to define a gap 506 therebetween that is slightly wider than an arm 510 of the spring 457.

With reference again to FIG. 21, the spring 457 is a torsion spring,which includes a coiled portion 508, an arm 510 connected to the coiledportion, and another arm 512 connected to the coiled portion. The coiledportion 508 is a generally circular coil including approximately three(3) coils of the wire used to form the spring 457. The coil 508 definesa center axis 514, and the spring 457 generates a resistive force whenthe arm 510 is pivoted about the center axis relative to the arm 512(and vice versa).

The spring 457 is arranged in the interior space 128. Specifically, thecoil 508 is supported by a mount 516 extending from the left lower shell120. The mount 516 defines a generally circular periphery having adiameter that is slightly smaller than a diameter of the coil 508, suchthat the mount extends through the coil.

As shown in FIG. 24, the arm 510 is positioned on the spring contactsurface 500 between the protrusion 502 and the second protrusion 504.The protrusions 502, 504 prevent the arm 510 from sliding off the springcontact surface 500 in the directions parallel to the axis 514. A width518 of the arm 510 is less than the gap 506. Accordingly, theprotrusions 502, 504 enable the arm 510 to move relative to the springcontact surface 500 in the direction 520 and in the direction 522 inresponse to the movement of the foot 456. The spring 457 includes anelbow 526 so that the arm 510 is in the proper position for beingpositioned on the spring contact surface 500.

As shown in FIG. 23, the arm 512 of the spring 457 is positioned againsta stop tab 524 of the left lower shell 120. The arm 512 remains in agenerally fixed position in response to pivoting of the foot 456.

The arm 510 of the spring 457 slides on the spring contact surface 500during pivoting of the foot 456 relative to the housing 104, which mayalternatively be described as pivoting of the housing relative to thefoot. The spring 457 biases the foot 456 toward the position of minimumcutting depth (FIG. 23). In this position, an end 527 of the arm 510 ispositioned adjacent to the protrusion 502. As the foot 456 is pivoted tothe position of maximum cutting depth (FIG. 21) the spring arm 510slides on the spring contact surface 500 such that the end 527 isseparated from the protrusion 502 by the distance 525. The arm 510slides on the spring contact surface 500 as a result of the axis 514being offset from the axis 482. Additionally, pivoting the foot 456 fromthe position of minimum cutting depth (FIG. 23) to the position ofmaximum cutting depth (FIG. 21) causes at least a portion of the cuttingwheel 296, 300 to be advanced through the cutting wheel passage 468.

Dust Port

As shown in FIGS. 25 and 26, the saw assembly 100 includes a dust portassembly 528, which includes a dust inlet or an inlet port 530, a dustchannel or central channel 476, a dust outlet or an outlet port 534, acoupling component or a connection structure 536, and a hose adapter538. The inlet port 530 is a generally circular opening formed in thelower right shell 124. The inlet port 530 is formed in the wall portion430 and is in fluid communication with the hinge receptacle 490 (FIG.22). The inlet port 530 defines a center point and has a diameter ofapproximately eight millimeters (8 mm). The center point of the inletportion 530 is aligned with the pivot axis 492 of the foot 456. As shownin FIG. 20, during a cutting operation the inlet port 530 is positionednear the point of intersection between the leading edge 452 of thecutting wheel 296, 300 and the cutting line 454. The inlet port 530 isaligned with the opening 478 and is juxtaposed with the protected spaced432 defined by the flange 428.

With reference to FIG. 21, the dust channel is provided as the centralchannel 476 in the cylindrical member 474 of the hinge structure 460.The dust channel 476, which may also be referred to as a conduitpassage, is a bore that extends from the opening 478 on a first side ofthe cylindrical member 474 to the opening 480 (FIG. 22) on an oppositeend of the cylindrical member. The dust channel 476 is a generallycylindrical channel that defines the longitudinal axis 482 (FIG. 22),which is coaxial with the pivot axis 492 (FIG. 22) of the foot 456.

As shown in FIG. 27, the outlet port 534 is an opening formed in thelower left shell 120. The outlet port 534 is in fluid communication withthe hinge receptacle 488 (FIG. 21). The outlet port 534 is also in fluidcommunication with the opening 480, the dust channel 476, the opening478, and the inlet port 530. The outlet port 534 is a generally circularport that defines a center point that is aligned with the pivot axis ofthe foot 456 (FIG. 22).

The connection structure 536 is formed in the lower left shell 120 anddefines a receptacle or a circular bore 540 that is concentric with theoutlet port 534. The connection structure 536 also includes numerousfriction ribs 542 and a wall 544. The friction ribs 542 extend radiallyinward from the circular bore 540 for approximately one millimeter (1mm). The friction ribs 542 are generally evenly spaced around theperiphery of the circular bore 540. The wall 544 terminates the circularbore 540.

As shown in FIG. 28, the adapter 538 includes a coupling component orinlet structure 546, a funnel portion 548, and an outlet structure 550.The adapter 538 is formed from injection molded thermoplastic. The inletstructure 546 is a generally cylindrical structure defining a centralopening 552 and an adapter passage 554. The outside diameter of theinlet structure 546 is approximately equal to an inside diameter of thecircular bore 540, such that the inlet structure is configured to matewith the connection structure 536 to secure the adapter 538 to thehousing 104. When the inlet structure 546 is mated with the connectionstructure 536, the adapter passage 554 is in fluid communication withthe outlet port 534. The outlet structure 550 is also a generallycylindrical structure defining a central opening 556 and an outletpassage 558.

The funnel portion 548 fluidly connects the adapter passage 554 of theinlet structure 546 to the outlet passage 558 of the outlet structure550. To this end, the funnel portion defines a dust channel (not shown)that is narrowest near the inlet structure 546 and that is widest nearthe outlet structure 550. The funnel portion 548 defines an elbow 562,such that the inlet structure 546 is offset from the outlet structure550.

As shown in FIG. 26, the dust port assembly 528 is used with a vacuumhose/tube 564, a vacuum source 566, and a collection bin 568 to drawdust generated by the cutting wheel 296, 300 to the collection bin. Touse the dust port assembly 528, first the adapter 538 is connected tothe saw assembly 100 by inserting the inlet structure 546 into the bore540 until the inlet structure contacts the bottom wall 544. The exteriorof the inlet structure 546 contacts the friction ribs 542 when it isinserted into the connection structure 536, such that a friction fit isestablished between the connection structure and the inlet structure.Due to the friction fit, the adapter 538 remains in a fixed positionrelative to the connection structure 536 without user intervention.Nonetheless, the adapter 538 is easily rotated about the pivot axis 492to a desired position. Next, the vacuum tube 564 is connected to theoutlet structure 550 of the adapter 538. The vacuum tube 564 includes afitting 570 that frictionally fits within the outlet structure 558. Toconnect the vacuum tube 564 to the adapter 538 the fitting 570 isinserted within the outlet structure 558.

Thereafter, the vacuum source 566 is energized and a workpiece W is cutwith the cutting wheel 296, 300. As the cutting wheel 296, 300 movesthrough the workpiece W dust and debris is generated at a point near theinlet port 530. Accordingly, when the vacuum source 566 is activated airand the dust and debris are drawn into the inlet port 530, through thedust channel 476, through the adapter passage 554, through the dustchannel 560, through the outlet passage 558, through a hose passage 572of the vacuum hose 564, and into the collection bin 568.

Base Lock Assembly

As shown in FIGS. 22 and 29, the saw assembly 100 includes a base lockassembly 576 having a clamp component 578 (FIG. 29) and a clamp actuator580 (FIG. 22). With reference to FIG. 29, the clamp component 578includes a clamping surface 582 and a bore structure 584 (shown inphantom). The clamping surface 582 is a portion of the gear housing 196that surrounds the bore structure 584. The clamping surface 582 isgenerally flat and defines a plane that is perpendicular to theworkpiece contact plane 434. The clamping surface 582 is positionedwithin the interior space 128.

The bore structure 584 is formed in the gear housing 196. The borestructure 584 defines a longitudinal axis 586 that is parallel to theaxis of rotation 268. The bore structure 584 includes a plurality ofinternal threads 588 (shown in phantom). The internal threads 588 areleft-handed threads.

The clamp actuator 580 includes a clamp component 590 (FIG. 29) and aknob 592 (FIG. 22). With reference to FIG. 30, the clamp component 590includes a post 594, a drive structure 596, and a clamping surface 598.The clamp component 590 is formed from metal. In other embodiments,however, the clamp component 590 is formed from injection moldedthermoplastic or another hard material.

The post 594 is generally cylindrical and includes a threaded portion600 and a smooth portion 602. The post 594 is approximately seventeenmillimeters (17 mm) in length. The threaded portion 600 includes a setof external threads 605 and has a length of approximately tenmillimeters (10 mm). The external threads 605 are “left-handed” threadsthat are sized to mesh with the internal threads 588 of the borestructure 584. The smooth portion 602 is positioned between the threadedportion 600 and the drive structure 596. The smooth portion 602 isgenerally cylindrical and has a length of approximately six millimeters(6 mm) and a diameter of approximately six millimeters (6 mm).

The drive structure 596 is positioned on an end of the clamp component590 that is opposite the threaded portion 600. The drive structure 596includes an exterior polygonal-shaped surface, which has six sides andcan be driven by an eight millimeter (8 mm) wrench/spanner. The drivestructure 596 has width that is wider than a width of the post 594 and alength of approximately nine millimeters (9 mm). The drive structure 596defines an internally threaded bore 604 centered about a longitudinalaxis 586 of the clamp component 590. The threaded bore 604 includes aset of “right-handed” internal threads 606.

The clamping surface 598 is positioned at the junction of the drivestructure 596 and the post 594 and is defined by an end surface of thedrive structure. The clamping surface 598 defines a plane that isparallel to the plane defined by the clamping surface 582.

As shown in FIG. 31, the knob 592 includes a hub 608, a lever 610, and atab 612 each of which is integrally formed from injection moldedthermoplastic. The hub 608 includes a drive structure 614 and an opening616. The drive structure 614 is correspondingly sized and shaped to matewith the drive structure 596. In particular, the drive structure 614includes an interior polygonal-shaped surface that mates with theexterior polygonal-shaped surface of the drive structure 596.

The opening 616 extends through the hub 608 and is centered about thelongitudinal axis 586 of the clamp component 590. A fastener 618 (FIG.27) extends through the opening 616 and into the threaded bore 604 toconnect the knob 592 to the clamp component 590. When the drivestructure 614 is mated with the drive structure 596, rotation of theknob 592 results in rotation of the clamp component 590.

The lever 610 extends from a first side of the hub 608. The lever 610defines a push surface 620 and a push surface 622. The push surfaces620, 622 are contacted when rotation of the lever 610 is desired.

The tab 612 extends from a side of the hub 608 opposite the lever 610.The tab 612, which may also be referred to herein as a limiter, includesa contact surface 624 on one side of the tab and a contact surface 626on an opposite side of the tab.

As shown in FIG. 32, when the clamping structure 590 is threadinglyreceived by the bore structure 584, the extension structure 462 extendsbetween the clamping surface 582 and the clamping surface 598. Theextension structure 462 remains positioned between the clamping surface582 and the clamping surface 598 during pivoting of the foot 456relative to the housing 104

The clamp actuator 580 is rotatable between a first actuator position(an unclamped position) and a second actuator position (a clampedposition). When the clamp actuator 580 is in the unclamped position theclamping surface 582 is spaced apart from the clamping surface 598 by anopen distance. The open distance is greater than a width 628 of theextension structure 462, such that the extension structure is able toadvance between the clamping surface 582 and the clamping surface 598when the clamp actuator 580 is in the unclamped position. In theunclamped position the base 458 is pivotal about pivot axis 492 relativeto the housing 104.

When the clamp actuator 580 is rotated counterclockwise to the clampedposition, the clamping surface 598 advances toward the clamping surface582. In particular, in the clamped position the clamping surface 598 isseparated from the clamping surface 582 by a closed distance. The closeddistance is less than the open distance and is approximately equal tothe width 628 of the extension arm 462. The closed distance positionsthe clamping surface 598 and the clamping surface 582, such that theextension structure 462 is clamped between the clamping surface 598 andthe clamping surface 582 so that pivoting of the base 458 relative tothe housing 104 is inhibited.

As shown in FIG. 27, the housing 104 includes a limiter 630 that ispositioned to interact with the tab 612 of the base lock assembly 576.In particular, the housing 104 includes a limiter 630 extending from anexterior surface of the lower left shell 120. The limiter 630 includesan arcuate structure 632 attached to the exterior surface. The arcuatestructure 632 includes a contact surface 634 at one end and a contactsurface 636 at the opposite end. If the arcuate structure 632 wereextended to form a circle, a center point of the circle would be alignedwith the longitudinal axis 586 of the clamp component 590.

The limiter 630 interacts with the tab 612 to prevent the clamp actuator580 from being rotated beyond the clamped position and from beingrotated beyond the unclamped position. In particular, rotation of theclamp actuator 580 in the clockwise direction (as viewed in FIG. 27) isprevented by physical interaction (i.e. contact) between the contactsurface 624 of the tab 612 and the contact surface 634 of the limiter630. Likewise, rotation of the clamp actuator 580 in thecounterclockwise direction (as viewed in FIG. 27) is prevented byphysical interaction (i.e. contact) between the contact surface 626 ofthe tab 612 and the contact surface 636 of the limiter 630.

The limiter 630 and the tab 612 prevent the clamp actuator 580 frombecoming over tightened and under tightened. In particular, interactionbetween the contact surface 624 and the contact surface 634 prevents theclamp actuator 580 from being rotated to a position in which the clampcomponent 590 becomes separated from the bore structure 584. In thisway, the clamp actuator 580 does not become lost or separated from thesaw assembly 100. Additionally, the interaction between the contactsurface 626 and the contact surface 636 ensures that the when these twosurfaces 626, 636 meet the clamp actuator 580 applies a consistentclamping force to the extension structure 462. The consistent clampingforce is one that has been determined to fix the pivotal position of thebase 458 securely over the life of the saw assembly 100. Accordingly,the limiter 630 and the tab 612 prevents the clamp actuator 580 frombeing rotated to a rotational position that applies a damaging clampingforce to the extension structure 462. The damaging clamping forcedeforms the extension structure 462 so that it does not pivot about thepivot axis 492 effectively.

Depth Gauge

As shown in FIG. 27, the saw assembly 100 includes a depth gaugeassembly 640, which includes an indicator projection 642 (FIG. 32), anindicator opening 644, a first depth gauge portion 646, and a secondgauge portion 648. With reference to the foot 456, as shown in FIG. 32,the indictor projection 642 includes an arm 650 and a marker 652. Thearm 650 extends from the upper end portion 496 of the extensionstructure 462. The marker 652 extends from the arm 650 in a directionparallel to the pivot axis 492.

Referring again to FIG. 27, the opening 644 is formed in the lower leftshell 120 of the housing 104. The opening 644 has a generallyarcuateshape of approximately the same radius as the opening 498 in theextension structure 462. The marker 652 is positioned to extend throughthe opening 644. The position of the marker 652 within the opening 644depends on the position of the foot 456 relative to the housing 104. Inparticular, when the foot 456 is in the position of minimum cuttingdepth (FIG. 33) the marker 652 is positioned at the bottom of theopening 644, and when the foot 456 is in the position of maximum cuttingdepth (FIG. 27) the marker 652 is positioned at the top of the opening644.

The depth gauge portion 646 is positioned on a first side of the opening644 and includes indicia denoting ⅛ inch, ¼ inch, ½ inch, and ¾ inchcutting depths. The depth gauge portion 648 is positioned on the secondside of the opening 644 and includes indicia denoting 0 mm, 5 mm, 10 mm,15 mm, and 20 mm cutting depths. Both the depth gauge portion 646 andthe depth gauge portion 648 are integrally formed into the lower leftshell 120.

The depth gauge assembly 640 is used to indicate the distance that thecutting wheel 296, 300 extends below the workpiece contact surface 466.For example, the foot 456 may be moved relative to the housing 104 untilthe marker 652 is aligned with a desired cutting depth as shown on thedepth gauge portion 646 or the depth gauge portion 648. When the desiredcutting depth is achieved, the foot 456 is locked in position relativeto the housing 104 with the base lock assembly 576.

T-Square Accessory

As shown in FIGS. 34 to 36, a T-square 660 may be used with the sawassembly 100. The T-square 660 includes a guide member 662 connected toa positioning rod 664 with a connector 666. The guide member 662includes a body 668, a guide structure 670, and numerous support ribs672. The body 668 is a generally flat member from which the guidestructure 670 extends. The support ribs 672 are positioned to contactthe body 668 and the guide structure 670, thereby increasing therigidity of the guide member 662. The body 668, the guide structure 670,and the support ribs 672 are integrally molded together in a monolithicpart formed from injection molded thermoplastic.

As shown in FIG. 35, the guide structure 670 defines a generally flatguide surface 674. The guide surface 674 is positioned against aworkpiece W (see FIG. 36) when the T-square 660 is in use. The guidesurface 674 is generally rectangular and has a length of approximatelyfifteen centimeters (15 cm) and a height of approximately twocentimeters (2 cm). The guide surface 674 is free from protrusions orother irregularities that may interfere or prohibit sliding of the guidemember 662 against the workpiece W.

The body 668 further defines a rod pocket 676 and a rod pocket 678. Therod pocket 676 defines an opening 680 in the guide structure 670 and anopening 682 in the body 668. The second rod pocket 678 defines anopening 684 in the guide structure 670 and a connector opening (notshown), which is substantially identical to the opening 682.

The positioning rod 664 is a generally straight rod having a generallyrectangular cross section. The positioning rod 664 has a length ofapproximately 25 centimeters (25 cm), a width of approximately 1centimeter (1 cm) and a thickness of approximately 0.3 centimeters (0.3cm). The positioning rod 664 defines a threaded opening 686. Anotherthreaded opening is positioned on the opposite end of the positioningrod 664, but is not visible since it is shown having received a portionof the connector 666. The positioning rod 664 is sized to extend throughthe opening 680 and the opening 684. The positioning rod 664 is formedfrom metal.

As shown in FIG. 35, the positioning rod 664 is received by the base458. To this end, the base 458 defines a rod channel 688 (FIG. 3) andincludes a connecting structure 690. The rod channel 688 has a lengththat is parallel to the axis of rotation 268.

The connecting structure 690 includes a fastener 692 and a clamp memberprovided as a square nut 694. The fastener 692 is threadingly receivedby the square nut 694. The connecting structure 690 is positioned withina clamp pocket 696 formed in the base 458. The clamp pocket 696 isfluidly connected to the rod channel 688, such that the fastener 692 isat least partially positionable within the rod channel.

The connector 666 includes a fastener 698 extending from a handle 700.The fastener 698 is sized to be threadingly received by the opening 686in the positioning rod 664. The handle 700 is fixedly connected to thefastener 698.

As shown in FIG. 35, the T-square 660 is assembled and connected to thebase 458 by inserting an end portion of the positioning rod 664 into therod pocket 678. The rod pocket 678 is positioned such that when thepositioning rod 664 is received therein, the positioning rod extendsfrom the guide structure 670 in a direction that is perpendicular to theguide surface 674. Next, the connector 666 is used to connect thepositioning rod 664 to the guide member 662. Thereafter, the positioningrod 664 is inserted into the rod channel 688 until the guide surface 674is a predetermined distance from the cutting wheel 296. Thereafter, thefastener 698 is advanced into the rod channel 688 to fix the position ofthe positioning rod 664.

As shown in FIG. 36, with the T-square 660 connected to the saw assembly100 a user may make rip cuts in a workpiece W along a desired cut path702. In particular, to use the T-square 660 the guide surface 674 ispositioned against an edge E of the workpiece W. Then the saw assembly100 is energized and moved along the cut path 702 to advance the cuttingwheel 296 through the workpiece W. By maintaining the guide surface 674against the edge E, the cutting wheel 296 is advanced through theworkpiece W by the predetermined distance from the edge E.

Attachment Structures

As shown in FIGS. 29 and 37, the gear housing 196 includes an attachmentbore 750 and an attachment bore 752. The attachment bore 750 defines alongitudinal axis 754 that is parallel to the axis of rotation 268. Theattachment bore 750 includes a plurality of internal threads. As shownin FIG. 33, the lower left shell 120, defines a circular opening 756having a center point positioned in alignment with the longitudinal axis754.

As shown in FIG. 37, the attachment bore 752 is also formed in the gearhousing 196. The attachment bore 752 includes a plurality of internalthreads. As shown in FIG. 19, the base 458 defines an opening 758 thatis positioned in alignment with the attachment bore 752 when the foot456 is in the position of the maximum cutting depth. When the foot 456is moved to positions other than the position of maximum cutting depth,the opening 758 is not positioned in alignment with the attachment bore752. Both the attachment bore 750 and the attachment bore 752 have thesame internal thread count/structure.

The attachment bore 750 and the attachment bore 752 are used to connectaccessories (not shown) to the saw assembly 100 or to connect the sawassembly 100 to an accessory element. For example, a handle (not shown)having a shaft with a threaded tip may be threadingly received by theattachment bore 750 by inserting the shaft through the opening 756 andinto the attachment bore.

As shown in FIG. 38, for example, the attachment bore 752 may be used toconnect the saw assembly 100 to a table saw assembly 760. The table sawassembly 760 includes a table 762 defining a countersunk bore 764 and acutting wheel opening (not shown). The saw assembly 100 is connected tothe table 762 by first positioning the foot 456 in the position ofmaximum cutting depth. Next, a fastening member 766 is inserted throughthe bore 764 in the table 762, through the opening 758 in the base 458,and into the threaded bore 752. With the saw assembly 100 connected tothe table 762, the cutting wheel 296 (not shown in FIG. 38) extendsthrough the cutting wheel opening and is positioned above a workpiecesupport surface 768 of the table 762. The saw assembly 100 and table sawassembly 760 are used to cut workpieces W in a manner similar to tablesaws known to those of ordinary skill in the art.

Miter Cutting Guide Accessory

As shown in FIGS. 39 and 40, a cutting guide 780 is provided for usewith the saw assembly 100. The cutting guide 780 includes a guidestructure 782 and a guide structure 784. The cutting guide 780 is formedfrom injection molded thermoplastic. The guide structure 782 is providedas a bevel cutting guide. The guide structure 784 is provided as a mitercutting guide.

The guide structure 782 includes a saw support 786 and a saw support788, both of which are attached to a base 790. The saw support 786defines a saw contact surface 792, a step structure 794, and a stepstructure 796. The saw contact surface 792 is a generally flat surfacethat is positioned in a plane.

The step structure 794 is offset from the saw contact surface 792 and ispositioned at a first end of the saw support 786. The step structure 796is also offset from the saw contact surface 792 and is positioned at anopposite end of the saw support 786. The saw contact surface 792 extendsbetween the step structure 794 and the step structure 796. The stepstructure 794 and the step structure 796 each define a contact surface798, 800 that is positioned perpendicular to the plane defined by thesaw contact surface 792.

The saw support 788 defines another saw contact surface 802. The sawcontact surface 802 is a generally flat surface that is positioned in aplane. The plane defined by the saw contact surface 792 intersects theplane defined by the saw contact surface 802 to define an angle ofintersection having a magnitude of ninety degrees (90°). In otherembodiments, the angle of intersection has a magnitude greater thaneighty degrees (80°) and less than one hundred degrees (100°).

The saw contact surface 802 is spaced apart from the saw contact surface792 so as to define a window or an elongated cutting slot 804 therebetween. The cutting slot 804 is oriented along a slot axis 806 andincludes a first slot portion 808, a second slot portion 810, and athird slot portion 812. The second slot portion 810 is contiguous withthe first slot portion 808 and the third slot portion 812. The secondslot portion 810 is interposed between the first slot portion 808 andthe third slot portion 812.

As shown in FIG. 41, the base 790 of the guide structure 782 defines afirst cavity 814 positioned below the cutting slot 804. The first cavity814 includes a first workpiece space 816, a first cutting member startspace 818 positioned on a first side of the first workpiece space 816,and a first cutting member end space 820 positioned on an oppositesecond side of the first workpiece space 816. The first workpiece space816 is positioned below the second slot portion 810 and receives aworkpiece W to be cut by the saw assembly 100 during a cuttingoperation. The first cutting member start space 818 is positioned belowthe first slot portion 808 and is where the cutting wheel 300 ispositioned at the beginning of the cutting operation. The first cuttingmember end space 820 is positioned below the third slot space 812 and iswhere the cutting wheel 300 is positioned at the end of the cuttingoperation.

The base 790 of the guide structure 782 includes a first sidewall 822, asecond sidewall 824, and end wall 826, and an end wall 828. The firstsidewall 822 and the second sidewall 824 are positioned generallyparallel to each other. The end wall 826 extends between the firstsidewall 822 and the second sidewall 824 at an end portion of the guidestructure 782. The end wall 828 is positioned at an opposite end portionof the guide structure 782 and extends between the first sidewall 822and the second sidewall 824.

As shown in FIG. 41, the base 790 of the guide structure 782 defines thefirst workpiece space 816. Specifically, the workpiece space 816 definedby a first workpiece passage 830 and a second workpiece passage 832. Thefirst workpiece passage 830 is formed in the first sidewall 822 and isdefined by a first lateral passage surface 834 that is spaced apart froma second lateral passage surface 836. The second workpiece passage 832is formed in the second sidewall 824 and is defined by a third lateralpassage surface 838 that is spaced apart from a fourth lateral passagesurface 840. The first workpiece passage 830 is spaced apart from thesecond workpiece passage 832 so as to define the first workpiece space816 there between.

The guide structure 782 further includes a guide wall 844 to assist inpositioning the cutting guide 780 on a workpiece W. The guide wall 844is positioned in the cavity 814 and defines a first guide surfaceportion 846. The guide surface portion 846 is positioned under thecutting slot 804. The guide surface portion 846 and the first lateralpassage surface 834 are positioned in a plane that includes bothsurfaces. The slot axis 806 (FIG. 40) is perpendicular to the plane inwhich the first lateral passage 834 and the guide surface portion 846are positioned.

As shown in FIG. 40, the saw support 786 defines a cutout 848 in the sawcontact surface 792. The cutout 848 is contiguous with the cutting slot804. The guide surface portion 846 is positioned under the cutout 848 sothat visualization of the guide surface portion is enhanced.

As shown in FIG. 39, the base 790 includes a reference indicia mark 842positioned on the first sidewall adjacent the first lateral passagesurface. The reference indicia mark 842 indicates a pivot point for usewith the guide structure 784, as described below.

As shown in FIG. 41, the saw support 786 also defines a first workpiececontact surface 850 and a second workpiece contact surface 852. Thefirst workpiece contact surface 850 is an underside portion of the sawsupport 786 and is generally parallel to the cutting slot 804. Thesecond workpiece contact surface 852 is an underside portion of the sawsupport 788 and is generally parallel to the cutting slot 804. Theworkpiece contact surface 850 and the workpiece contact surface 852 arepositioned in the cavity 814. It is noted that the cutting slot 804 maybe defined by the first workpiece contact surface 850 being spaced apartfrom the second workpiece contact surface 852.

As shown in FIG. 39, the guide structure 784 extends from the guidestructure 782 and includes a first guide wall 854, a second guide wall856, and numerous support ribs 858 that extend between the first guidewall and the second guide wall. The first guide wall 854 extends fromthe base 790 and defines a first guide surface 860. The first guide wall854 includes a leg 862 (FIG. 41) attached the base 790. The leg 862supports the guide structure 784 during use of the cutting guide 780.

The second guide wall 856 extends from the base 790 and defines a secondguide surface 864. The second guide wall 856 extends perpendicularlyfrom the second sidewall 856 of the base 790. The second guide wall 856intersects the first guide wall 854 to define a corner 866.

The second guide wall 856 includes a leg 868 and a leg 870 (FIG. 41).The leg 868 extends downwardly from the second guide wall 856 and, inparticular, extends downwardly from the corner 866. The leg 870 extendsdownwardly from the second guide wall 856. The leg 868 and the leg 870are spaced apart to define a third workpiece passage 872. The leg 868and the leg 862 are spaced apart to define a fourth workpiece passage874.

The first guide wall 854 and the second guide wall 856 form an anglehaving a magnitude between thirty degrees (30°) and sixty degrees (60°).The angle between the first guide wall 854 and the second guide wall 856is forty five degrees (45°). The angle between the first guide wall 854and the second guide wall 856 is used to make miter cuts in theworkpiece W at the angle. The guide structure 784 includes numerousreference indicia 876 (FIG. 40) and magnitudes formed on the first guidewall 854, the second guide wall 856, and the ribs 858. The secondindicia 876 are used to position the guide structure 784 when makingcuts that are different than the angle between the first guide wall 856and the second guide wall 856.

The guide structure 784 further includes a clamp structure 878 extendingfrom the second guide wall 856. The clamp structure 878 includes a flatclamp surface 880 and numerous support ribs 882. The clamp structure 878receives a clamping force, which connects the cutting guide 780 to aworkpiece W. The flat clamp surface 880 typically contacts a clampmember and the support ribs 882 increase the structural integrity of thecutting guide 780 so that it is not deformed or otherwise damage as aresult of the clamping force.

As shown in FIG. 41, the guide structure 784 includes a second workpiecespace 884 that receives a workpiece W. The second workpiece space 884 isdefined by the third workpiece passage 872 and the fourth workpiecepassage 874. The second workpiece space 884 is aligned with the firstworkpiece space 816, such that a workpiece W extending through the firstworkpiece passage 830 extends through the first workpiece space and thesecond workpiece space.

As shown in FIGS. 42 and 43, in operation, the cutting guide 780 is usedto make bevel cuts and miter cuts on a workpiece W with the saw assembly100 being equipped with the flush cutting wheel 300. The guide structure782 is used to make a bevel cut. First, the workpiece W is positioned inthe workpiece space 816. The workpiece W is positioned against the firstlateral passage surface 834, the guide wall 844, the leg 868, the firstworkpiece contact surface 850, and the second workpiece contact surface852. This arrangement positions the cutting slot 804 perpendicularly tothe edge E of the workpiece W.

Next, the user “fine tunes” the position of the cutting guide 780 on theworkpiece W. To do this, the user looks through the cutout 848 andlocates first guide surface portion 846. The guide surface portion 846is positioned a predetermined distance from the desired cutting paththrough the workpiece W. Accordingly, the position of the cutting guide780 is adjusted until the guide surface portion 846 is the predetermineddistance from the desired cutting path. Thereafter, a clamp (not shown)is affixed to the clamp structure 878 and the workpiece W to preventfurther movement of the cutting guide 780 relative to the workpiece.

The user next positions the saw assembly 100 on the cutting guide 780with the workpiece contact surface 466 of the foot 456 positionedagainst the first saw contact surface 792 and with the flange 428positioned against the second saw contact surface 802. The first guidestructure 782 supports the saw assembly 100 on two sides to ensure thatthe saw assembly is maintained at the proper bevel angle for theduration of the cut.

As shown in FIG. 43, the flush cutting wheel 300 extends though thecutting slot 804 into the cutting member start space 818 of the cavity814. The start space 818 of the cavity 814 provides the user with aregion in which the saw assembly 100 can be energized to bring thecutting wheel 300 up to full rotational speed without the cutting wheelbeing in contact with the workpiece W. After the saw assembly 100 isenergized the saw assembly 100 is moved toward the end wall 828 throughthe workpiece to cut the workpiece at a bevel angle of forty fivedegrees (45°).

The saw assembly 100 is moved toward the end wall 828 with the workpiececontact surface 466 positioned against the first saw contact surface 792until the leading sidewall 886 of the foot 456 contacts the stepstructure 794, which is positioned to stop any additional forwardmovement of the saw assembly 100. At this point the cutting operation iscomplete and the user may release the paddle 344 to deenergize theelectric motor 136. It is noted that the step structure 796 stopsmovement of the saw assembly 100 in the reward direction by contacting atrailing sidewall 888 of the base 458.

The guide structure 784 is used to make miter cuts with the saw assembly100. To prepare the saw assembly 100 to make miter cuts the usertypically connects the flat cutting wheel 296 to the arbor assembly 148;although, the flush cutting wheel 300 is also usable. Next, the cuttingguide 780 is positioned on the workpiece W. In particular, the workpieceW is positioned against the guide wall 844 and the leg 868 in the firstworkpiece space 816 and the second workpiece space 884. Next the flange428 is positioned against the first guide surface 860. Thereafter, therotating cutting wheel 296 is moved through the workpiece with theflange 428 being maintained against the first guide surface 860.

In the above configuration, the first guide surface 860 is positioned tomake a forty five degree (45°) miter cut through the workpiece. Thecutting guide 780 is pivotable about the first lateral passage surface834 to a desired cutting angle as indicated by the indicia 876.

Crown Molding Cutting Guide

As shown in FIGS. 44 to 47, a cutting guide 900 is provided for use withthe saw assembly 100. The cutting guide 900 includes a first guidestructure 902 connected to a second guide structure 904 by anintermediate part 906. The cutting guide 900 is formed from injectionmolded thermoplastic.

As shown in FIG. 44, the first guide structure 902 includes a first sawsupport 908 and a second saw support 910, both of which are attached toa base 912. The first saw support 908 defines a first saw contactsurface 914, a first step structure 916, and a second step structure918. The first saw contact surface 914 is a generally flat surface thatis positioned in a plane.

The first step structure 916 is offset from the first saw contactsurface 914 and is positioned at a first end of the first saw support908. The second step structure 918 is also offset from the first sawcontact surface 914 and is positioned at an opposite second end of thefirst saw support 908. The first step structure 916 and the second stepstructure 918 each define a contact surface 920, 922 that is positionedperpendicular to the plane defined by the first saw contact surface 914.

The second saw support 910 defines a second saw contact surface 924. Thesecond saw contact 924 surface is a generally flat surface that ispositioned in a plane. The plane defined by the first saw contactsurface 914 intersects the plane defined by the second saw contactsurface 924 to define an angle of intersection θ1 having a magnitude ofninety degrees (90°). In other embodiments, the angle of intersection θ1has a magnitude greater than eighty degrees (80°) and less than onehundred degrees (100°).

As shown in FIG. 45, the second saw contact surface 924 is spaced apartfrom the first saw contact surface 914 to as to define a first elongatedcutting slot 926 there between. The cutting slot 926 is oriented along aslot axis 928 and includes a first slot portion 930, a second slotportion 932, and a third slot portion 934. The second slot portion 932is contiguous with the first slot portion 930 and the third slot portion934. The second slot portion 932 is interposed between the first slotportion 930 and the third slot portion 934.

With reference to FIG. 47, the base 912 of the first guide structure 902defines a first cavity 936 positioned below the cutting slot 926. Thefirst cavity 936 includes a first workpiece space 938, a first cuttingmember start space 940 positioned on a first side of the first workpiecespace, and a first cutting member end space 942 positioned on anopposite second side of the first workpiece space. The first workpiecespace 938 is positioned below the second slot portion 932 and receives aworkpiece W to be cut by the saw assembly 100 during a cuttingoperation. The first cutting member start space 940 is positioned belowthe first slot portion 930 and is where the cutting wheel 300 ispositioned at the beginning of the cutting operation. The first cuttingmember end space 942 is positioned below the third slot portion 934 andis where the cutting wheel 300 is positioned at the end of the cuttingoperation.

The base 912 of the first guide structure 902 includes a first sidewall944, a second sidewall 946, an end wall 948, and a common end wall 950.The first sidewall 944 and the second sidewall 946 are positionedgenerally parallel to each other. The first end wall 948 extends betweenthe first sidewall 944 and the second sidewall 946. The common end wall950 is positioned at a guide end portion of the first guide structure902 and extends between the first sidewall 944 and the second sidewall946 and also the sidewalls of the guide structure 904.

As shown in FIG. 46, the base 912 of the first guide structure 902defines the first workpiece space 938. The workpiece space 938 isdefined by a first workpiece passage 952 and a second workpiece passage954. The first workpiece passage 952 is formed in the first sidewall 944and is defined by a first passage surface 956 that is spaced apart froma second passage surface 958. The second workpiece passage 954 is formedin the second sidewall 946 and is defined by a third passage surface 960that is spaced apart from a fourth passage surface 962. The firstworkpiece passage 952 is spaced apart from the second workpiece passage954 so as to define the first workpiece space 938 there between.

As shown in FIG. 47, the first guide structure 902 includes a firstguide wall 964 and a second guide wall 966 to assist in positioning thecutting guide 900 on a workpiece W. The first guide wall 964 ispositioned in the cavity 936 and defines a first guide surface portion968. The second guide wall 966 is positioned in the cavity 936 anddefines a second guide surface portion 970. The first guide surfaceportion 968 and the second guide surface portion 970 are positionedunder the cutting slot 926.

As shown in FIG. 45, the first saw support 908 defines a first cutout972 and a second cutout 974 in the first saw contact surface 914. Thefirst cutout 972 and the second cutout 974 are each contiguous with thecutting slot 926. The guide surface portion 968 is positioned under thefirst cutout 974 so that visualization of the first guide surfaceportion is enhanced. The guide surface portion 970 is positioned underthe second cutout 972 so that visualization of the second guide surfaceportion is enhanced.

With reference to FIG. 47, the first guide structure 902 also defines afirst workpiece contact surface 976 and a second workpiece contactsurface 978. The first workpiece contact surface 976 is an undersideportion of the saw support 910 that is generally parallel to the cuttingslot 926. The second workpiece contact surface 978 is an undersideportion of the saw support 908 that is generally parallel to the cuttingslot 926. The workpiece contact surface 976 and the workpiece contactsurface 978 are positioned in the cavity 936.

The guide structure 904 is substantially identical to the guidestructure 902. However, for completeness the guide structure 904 isdescribed in detail. The guide structure 904 includes a saw support 980and a saw support 982, both of which are attached to a base 984. Thefirst saw support 980 defines a first saw contact surface 986, a firststep structure 988, and a second step structure 990.

The second saw support 982 of the guide structure 904 defines a secondsaw contact surface 992. The plane defined by the first saw contactsurface 986 intersects the plane defined by the second saw contactsurface 992 to define an angle of intersection θ2 having a magnitude ofninety degrees (90°). In other embodiments, the angle of intersection θ2has a magnitude greater than eighty degrees (80°) and less than onehundred degrees (100°).

The second saw contact surface 992 is spaced apart from the first sawcontact surface 986 so as to define a cutting slot 994 there between.The cutting slot 994 is oriented along a slot axis 995 and includes afirst slot portion 996, a second slot portion 998, and a third slotportion 1000. The slot axis 995 and the slot axis 928 intersect at anacute angle θ (FIG. 44). The acute angle θ has a magnitude that isgreater than forty five degrees (45°) and less than seventy five degrees(75°).

As shown in FIGS. 46 and 47, the base 984 of the guide structure 904defines a cavity 1002 positioned below the cutting slot 994. The cavity1002 includes a workpiece space 1004, a cutting member start space 1006positioned on a first side of the first workpiece space 1004, and afirst cutting member end space 1008 positioned on an opposite secondside of the first workpiece space 1004. The first workpiece space 1004is positioned below the second slot portion 998 and receives a workpieceW to be cut by the saw assembly 100 during a cutting operation. Thefirst cutting member start space 1006 is positioned below the first slotportion 996 and is where the cutting wheel 300 is positioned at thebeginning of the cutting operation. The first cutting member end space1008 is positioned below the third slot space 1000 and is where thecutting wheel 300 is positioned at the end of the cutting operation.

The base 984 of guide structure 904 includes first sidewall 1010, asecond sidewall 1012, and end wall 1014, and the common sidewall/endwall 950. The first sidewall 1010 and the second sidewall 1012 arepositioned generally parallel to each other. The first end wall 1014extends between the first sidewall 1010 and the second sidewall 1012.The common end wall 950 is positioned at a guide end portion of thefirst guide structure 902 and extends between the first sidewall 1010,the second sidewall 1012, and the also the sidewalls 944, 946 of theother guide structure 902.

As shown in FIG. 46, the base 984 of the guide structure 904 defines theworkpiece space 1004. The workpiece space 1004 is defined by a firstworkpiece passage 1018 and a second workpiece passage 1020. The firstworkpiece passage 1018 is formed in the first sidewall 1010 and isdefined by a first passage surface 1022 that is spaced apart from asecond passage surface 1024. The second workpiece passage 1020 is formedin the second sidewall 1012 and is defined by a third passage surface1026 that is spaced apart from a fourth passage surface 1028. The firstworkpiece passage 1018 is spaced apart from the second workpiece passage1020 so as to define the workpiece space 1004 there between.

The guide structure 904 includes the guide wall 964 and the guide wall966 to assist in positioning the cutting guide 900 on a workpiece. Thefirst guide wall 964 is positioned in the cavity 1002 and defines afirst guide surface portion 1034. The first guide surface portion 1034is positioned under the cutting slot 994. The passage surface 956, thepassage surface 1022, the guide surface portion 968, and the guidesurface portion 1034 lie in a plane 1038. The second guide wall 966 ispositioned in the cavity 1002 and defines a second guide surface portion1036. The second guide surface portion 1036 is positioned under thecutting slot 994. The passage surface 958, the passage surface 1024, theguide surface portion 970, and the guide surface portion 1036 all lie ina second plane 1040 that is parallel to the plane 1038.

The saw support 980 defines a cutout 1042 and a cutout 1044 in the firstsaw contact surface 986. The cutout 1042 and the cutout 1044 are eachcontiguous with the cutting slot 994. The guide surface portion 1036 ispositioned under the cutout 1042 so that visualization of the guidesurface portion 1036 is enhanced. The guide surface portion 1034 ispositioned under the cutout 1044 so that visualization of the guidesurface portion 1034 is enhanced.

The guide structure 904 also defines a first workpiece contact surface1046 and a second workpiece contact surface 1048. The first workpiececontact surface 1046 is an underside portion of the saw support 980 thatis generally parallel to the cutting slot 994. The second workpiececontact surface 1048 is an underside portion of the saw support 982 thatis generally parallel to the cutting slot 994. The workpiece contactsurface 1046 and the workpiece contact surface 1048 are positioned inthe cavity 1002.

The intermediate part 906 is positioned between first guide structure902 and the second guide structure 904. The intermediate part 906 isconnected to the sidewall 946 and the sidewall 1012 and fixes theposition of the guide structure 902 relative to the guide structure 904.An interguide space 1050 is defined below the intermediate part 906.Since the guide structure 902 is spaced apart from the guide structure904 a space exists there between and is referred to as the interguidespace 1050.

The intermediate part 906 includes a first abutment structure 1052 and asecond abutment structure 1054. The first abutment structure 1052 islocated in the cavity 1002, the interguide space 1050, and the cavity936. Accordingly, the abutment structure 1052 is positioned under boththe cutting slot 926 and the cutting slot 994. The abutment structure1052 defines an abutment surface 1056 against which a workpiece ispositioned during cutting operations. The abutment structure 1052includes the guide wall portion 970 and the guide wall portion 1036. Thepassage surface 958, the passage surface 1024, and the abutment surface1056 lie in the plane 1040.

The abutment structure 1054 is located in the cavity 936, the interguidespace 1050, and the cavity 1002. Accordingly, the abutment structure1054 is positioned under both the cutting slot 926 and the cutting slot994. The abutment structure 1054 defines an abutment surface 1058against which a workpiece is positioned during cutting operations. Theabutment structure 1054 includes the guide wall portion 968 and theguide wall portion 1034. The passage surface 956, the passage surface1022, and the abutment surface 1058 lie in the plane 1038.

The intermediate part 906 further includes a clamp structure 1060including a flat clamp surface 1062 and numerous support ribs 1064 Theclamp structure 1060 receives a clamping force, which connects thecutting guide 900 to the workpiece. The support ribs 1064 increase thestructural integrity of the cutting guide 900 so that it is not deformedor otherwise damaged as a result of the clamping force.

In operation, the cutting guide 900 is used to guide the cutting wheel300 of the saw assembly 100 through a workpiece. Specifically, thecutting guide 900 is used to make a compound miter cut in a workpiece. Acompound miter cut is a cut that is beveled and mitered. These type ofcuts are frequency performed when cutting sections of crown molding tobe joined at an inside or an outside corner of the room.

To make a cut with the cutting guide 900 the workpiece is positioned inone or more of the workpiece space 938 and the workpiece space 1004. Anedge of the workpiece is positioned against one or more of the abutmentsurface 1056 and the abutment surface 1058. The cutting guide 900 ismoved along the workpiece until the desired line of cut is aligned withthe one of the guide surface portions 968, 970, 1034, 1036 which arevisible through the cutouts 972, 974, 1042, 1044. Depending on thedesired cutting orientation a face of the workpiece may be positionedagainst or away from the workpiece contact surfaces 976, 978, 1046,1048. Also, the saw assembly 100 should be equipped with the flushcutting wheel 300 when being used with the cutting guide 900. After thecutting guide 900 has been aligned, a cutting operation is performed insame manner as is performed with the bevel guide structure 782 describedabove.

Features of the Foot Related to Miter Cutting

Guide and Crown Molding Cutting Guide

The foot 456 of the saw assembly 100 is suited for operation with themiter cutting guide 780 and the crown molding cutting guide 900. Asshown in FIGS. 48 and 49, the base 458 of the foot 456 includes a mainportion 1110, a first cantilevered portion 1112, and a secondcantilevered portion 1114. The main portion 1110 includes an upper basesurface 1116, a lower base surface 1118, and a lateral sidewall surface1120. The lower base surface 1118 is positioned against the saw contactsurface 792 during cutting operations in which the cutting guide 780 isused. The lateral sidewall 1120 surface extends between the lower basesurface 1118 and the upper base surface 1116.

The first cantilevered portion 1112 extends laterally from the mainportion 1110 and terminates to define a leading surface 1122 of thelateral sidewall surface 1120. The leading surface 1122 is beveled withrespect to the lower base surface 1118. The second cantilevered portion1114 also extends laterally from the main portion 1110 and terminates todefine a trailing surface 1124 of the lateral sidewall surface 1120. Thetrailing surface 1124 is also beveled with respect to the lower basesurface 1118. The first cantilevered portion 1112 and the secondcantilevered portion 1114 are spaced apart from each other to define thecutting member opening or cutting wheel passage 468.

As shown in FIG. 49, when the base 458 is viewed in a cross section theleading surface 1122 and the lower base surface 1118 define an angle1126 of approximately one hundred thirty five degrees (135°). Similarly,when the base 458 is viewed in cross section the trailing surface 1124and the lower base surface 1118 define an angle 1128 of approximatelyone hundred thirty five degrees (135°). In another embodiment of thefoot 456, the angle defined by the leading surface 1122 and lower basesurface 1118 and the angle defined by the trailing surface 1124 and thelower base surface 1118 may be greater than one hundred twenty degrees(120°) and less than one hundred fifty degrees (150°).

As shown in FIG. 50, the above-described structure of the foot 456prevents any portion of the foot from extending below the cutting slot804 during cutting operations in which the cutting guide 780 and thecutting guide 900 are utilized. If the foot 456 were to extend below thecutting slot 804 and into the cavity 814, the foot would abut theworkpiece W as the user attempts to slide the saw assembly 100 towardworkpiece, thereby preventing cutting of the workpiece. Accordingly, thefoot 456 enables the flush cutting wheel 300 to extend through thecutting slot 804, while preventing the base 458 from extending throughthe cutting slot (i.e. the base is spaced apart from the cutting slot)when the lower base surface 1118 is positioned in contact with the sawcontact surface 792 (FIG. 39) and the flange 428 is positioned incontact with the saw contact surface 802 (FIG. 39).

Additionally, as described above with respect to the guard assembly 422,the beveled surface 450 of the guard ensures that the guard is spacedapart from the cutting slot 804 and ensures that no portion of the guardassembly 422 extends through the cutting slot where it could abut theworkpiece and interfere with a cutting operation.

Deburring Accessory

As shown in FIGs. 51 to 54, the saw assembly 100 is includes a fastenerassembly or a deburring accessory 1150. The deburring accessory 1150includes a fastener structure or support structure 1152 and an abrasivemember or abrasive element 1154. As shown in FIG. 54, the supportstructure 1152 includes a post or a shaft 1156, a platform or a shoulder1158, and a drive portion or a head 1160. The support structure 1152 isformed from metal. In another embodiment of the deburring accessory1150, the support structure 1152 is formed from hard plastic.

The shaft 1156 includes a threaded portion 1162 and an unthreadedportion 1164. The threaded portion 1162 includes a set of externalthreads sized to be threadingly received by the opening 1167 (FIG. 37)in the driveshaft 260 of the arbor assembly 148 to connect the deburringaccessory 1150 to the saw assembly 100. The unthreaded portion 1164extends from the threaded portion 1162.

The shoulder 1158 extends from the unthreaded portion 1164 and from thehead 1160. The shoulder 1158 includes a lower clamping surface or alower seat 1166 that is positioned against the cutting wheel 296, anupper support surface or an upper seat 1168 that supports the abrasiveelement 1154, and a washer recess 1170. The shoulder 1158 defines agenerally circular periphery and has a diameter of approximately twentyone millimeters (21 mm). The upper seat 1168 extends from the head 1160for approximately six millimeters (6.0 mm). The washer recess 1170 isdefined in the shoulder 1158 and is located adjacent to the lower seat1166. The washer recess 1170 extends around the shaft 1156.

As shown in FIG. 53, the head 1160 extends from the shoulder 1158 andthe unthreaded portion 1164. The head 1160 defines a generally circularperiphery and has a diameter of approximately nine millimeters (9.0 mm).The head 1160 defines a tool opening or a recess 1172 having a drivesurface. The recess 1172 is polygonal-shaped and is configured toreceive a fastening tool, such as a hex key (not shown).

The abrasive element 1154 is connected to the head 1160 and the shoulder1158. The abrasive element 1154 includes a grinding stone 1174 definingan interior surface 1176 and a central passage 1178, a lower surface1180, and an exterior side surface having a tapered exterior surfaceportion 1182. The abrasive element 1154 is secured to the supportstructure 1152 so that the head 1160 is located within the centralpassage 1178. In particular, the interior surface 1176 is secured to anexterior side surface of the drive portion and the lower surface 1180 issecured to the upper seat 1168.

As shown in FIG. 51, the tapered exterior surface 1182 is a generallyconical deburring surface. At the bottom of the deburring surface(nearest the shoulder 1158) the abrasive element has a width ofapproximately twenty one millimeters (21 mm). At the top of thedeburring surface (positioned furthest from the shoulder 1158) theabrasive element 1157 has a width of approximately thirteen millimeters(13.0 mm).

The grinding stone 1174 of the abrasive element is formed from aluminumoxide. Specifically, the abrasive element may be provided as thealuminum oxide as provided in the Dremel 952 Aluminum Oxide GrindingStone manufactured by the Robert Bosch Tool Corporation. In analternative embodiment of the deburring accessory 1150, the abrasiveelement 1154 is formed from silicon carbide, such as the silicon carbideas provided in the Dremel 84922 Silicon Carbide Grinding Stonemanufactured by the Robert Bosch Tool Corporation. In yet anotheralternative embodiment of the deburring accessory 1150 the abrasiveelement 1154 is formed from industrial diamonds, any alumina-basedabrasive, cubic boron nitride (“CBN”), and the like.

The deburring accessory 1150 is used to secure the cutting wheel 296 tothe saw assembly 100 in place of the arbor bolt 284 (FIG. 1) and thewasher 292 (FIG. 1). The threaded portion 1162 is threaded into theopening 1167 in the driveshaft 260. When the deburring accessory 1150 istightened onto the driveshaft 260, the cutting wheel 296 is clampedbetween the lower surface 1180 and the spacer 288 (FIG. 1) for rotationwith the driveshaft.

After securing the deburring accessory 1150 and the cutting wheel 296 tothe driveshaft 260, the saw assembly is used to perform a cuttingoperation on a pipe or other tubular structure. As a result of thecutting operation a burr 1184 (FIG. 54) is formed on the cut edge of thepipe.

After performing the cutting operating, the deburring accessory 1150 isused to remove the burr 1184 without requiring any changes orconfiguration of the saw assembly 100. The abrasive element 1154 of thedeburring accessory 1150 is used to smooth the cut edge of a pipe, tube,or conduit that has been cut by the cutting wheel 296. Specifically, theabrasive element 1154 is used to remove the burr or ridge formed on thecut end of the pipe after the pipe is cut with the cutting wheel. To usethe abrasive element 1154, the rotating conical deburring surface 1182is urged against the burr or ridge to wear away the bun or ridge.

As shown in FIG. 54, the conical shape of the abrasive element 1154uniformly removes the bun or ridge from the inside edge of the pipe P1,P2. The conical deburring surface 1182 is positionable against theinside edge of a pipe having an inside diameter that is greater than thediameter of the top of the deburring surface and that is less than thediameter of the bottom of the deburring surface. The pipe P1 has aninside diameter of approximately one half inch (0.5 in), and the pipe P2has an inside diameter of approximately the three quarters of one inch(0.75 in). The abrasive element 1154 uniformly removes the burr 1184 orridge since the conical deburring surface 1182 contacts most or all ofthe inside edge of the pipe at the same time.

In addition to being usable with the saw assembly 100, the deburringaccessory 1150 is also usable with other saw assemblies, grinders, andpower cutting tools. For example, the deburring accessory 1150 is usablewith circular saws and grinders that are typically used to cut metalpipe/conduit. Additionally, the deburring accessory 1150 is usable with,for example, portable band saws, which are typically used to cut metalpipe/conduit.

In another embodiment of the deburring accessory 1150, the head 1160 andthe shaft 1156 are connected together and are separate from the shoulder1158 and the abrasive member 1154. In this embodiment, the head 1160 andthe shaft 1156 are provided as a separate bolt (not shown) that issimilar to the arbor bolt 284 (FIG. 1). The shoulder 1158 defines anopening having a diameter larger than a diameter of the shaft 1156, butsmaller than the diameter/width of the head 1160 so that the head ispositioned against the shoulder when the deburring accessory 1150 isconnected to the saw assembly 100.

While the disclosure has been illustrated and described in detail in thedrawings and foregoing description, the same should be considered asillustrative and not restrictive in character. It is understood thatonly the preferred embodiments have been presented and that all changes,modifications and further applications that come within the spirit ofthe disclosure are desired to be protected.

What is claimed is:
 1. A saw assembly comprising: a drive memberconfigured to be moved in a repeating pattern; a motor configured tomove said drive member in said repeating pattern; a housing defining aninterior space in which said motor is positioned; and a foot including(i) a base having an upper surface and a lower work piece contactsurface, and (ii) a conduit structure secured to said upper surface ofsaid base, wherein said housing is pivotably mounted to said conduitstructure, wherein said conduit structure defines a first conduitopening, a second conduit opening, and a conduit passage extendingtherebetween, and wherein said housing defines (i) a dust inletpositioned in fluid communication with said first conduit opening, and(ii) a dust outlet positioned in fluid communication with said secondconduit opening.
 2. The saw assembly of claim 1, further comprising (i)a concave guard attached to said housing, and (ii) a saw member coupledto said drive member, wherein: said concave guard defines a protectedspace, said saw member is at least partially positioned in saidprotected space, and said dust inlet is juxtaposed to said protectedspace.
 3. The saw assembly of claim 1, further comprising a hose adapterdefining an adapter passage and having a first coupling component,wherein: said housing further includes a second coupling componentconfigured to mate with said first coupling component so as to securesaid hose adapter to said housing, and when said second couplingcomponent is mated with said first coupling component, said adapterpassage is positioned in fluid communication with said dust outlet. 4.The saw assembly of claim 3, further comprising a vacuum hose defininghose passage, wherein: said vacuum hose is configured to be secured tosaid hose adapter, and when said vacuum hose is secured to said hoseadaptor, said hose passage is positioned in fluid communication withsaid adapter passage.
 5. The saw assembly of claim 3, wherein: saidfirst coupling component includes a cylindrical end portion of said hoseadapter, said second coupling component includes a receptacle structurepositioned in fluid communication with said dust outlet, and saidreceptacle structure is configured to receive said cylindrical endportion in a friction fit manner.
 6. The saw assembly of claim 1,wherein: said conduit structure defines a cylindrical passage having acentral axis, and said housing pivots in relation to said foot aboutsaid central axis.
 7. The saw assembly of claim 1, further comprising aspring positioned in said interior space, wherein: said foot furtherincludes an extension structure secured to said upper surface of saidbase, said extension structure defines a spring arm contact surface, andsaid spring includes a spring arm positioned in contact with said springarm contact surface.
 8. A saw assembly comprising: a drive memberconfigured to be moved in a repeating pattern; a motor configured tomove said drive member in said repeating pattern; a housing defining aninterior space in which said motor is positioned; and a foot including(i) a base having an upper surface and a lower work piece contactsurface, and (ii) a conduit structure secured to said upper surface ofsaid base, wherein said housing is pivotably mounted to said conduitstructure, wherein said housing defines a dust inlet and a dust outlet,wherein said housing includes (i) a first receptacle structurepositioned in fluid communication with said dust inlet, and (ii) asecond receptacle structure positioned in fluid communication with saiddust outlet, wherein said conduit includes (i) a first conduit endportion defining a first conduit opening, and (ii) a second conduit endportion defining a second conduit opening, wherein said first conduitend portion is received in said first receptacle structure so that saiddust inlet is positioned in fluid communication with said first conduitopening, and wherein said second conduit end portion is received in saidsecond receptacle structure so that said dust outlet is positioned influid communication with said second conduit opening.
 9. The sawassembly of claim 8, wherein said conduit structure further defines aconduit passage extending between said first conduit opening and saidsecond conduit opening.
 10. The saw assembly of claim 8, furthercomprising (i) a concave guard attached to said housing, and (ii) a sawmember coupled to said drive member, wherein: said concave guard definesa protected space, said saw member is at least partially positioned insaid protected space, and said dust inlet is juxtaposed to saidprotected space.
 11. The saw assembly of claim 8, further comprising ahose adapter defining an adapter passage and having a first couplingcomponent, wherein: said housing further includes a second couplingcomponent configured to mate with said first coupling component so as tosecure said hose adapter to said housing, and when said second couplingcomponent is mated with said first coupling component, said adapterpassage is positioned in fluid communication with said dust outlet. 12.The saw assembly of claim 11, further comprising a vacuum hose defininghose passage, wherein: said vacuum hose is configured to be secured tosaid hose adapter, and when said vacuum hose is secured to said hoseadapted, said hose passage is positioned in fluid communication withsaid adapter passage.
 13. The saw assembly of claim 11, wherein: saidfirst coupling component includes a cylindrical end portion of said hoseadapter, said second coupling component includes a third receptaclestructure positioned in fluid communication with said dust outlet, andsaid third receptacle structure is configured to receive saidcylindrical end portion in a friction fit manner.
 14. The saw assemblyof claim 8, wherein: said conduit structure defines a cylindricalpassage having a central axis, and said housing pivots in relation tosaid foot about said central axis.
 15. The saw assembly of claim 8,further comprising a spring positioned in said interior space, wherein:said foot further includes an extension structure secured to said uppersurface of said base, said extension structure defines a spring armcontact surface, and said spring includes a spring arm positioned incontact with said spring arm contact surface.
 16. The saw assembly ofclaim 8, wherein: said first receptacle structure pivots in relation tosaid first conduit end portion during pivoting of said housing inrelation to said conduit structure, and said second receptacle structurepivots in relation to said second conduit end portion during pivoting ofsaid housing in relation to said conduit structure.